Power converter including a recirculating snubber

ABSTRACT

A power converter includes a first rectifier circuit having a pair of first rectifier circuit output terminals and a second rectifier circuit having a pair of second rectifier circuit output terminals, a snubber circuit comprising a first diode and a first capacitor connected to each other at a first node and connecting the pair of first rectifier circuit output terminals, a second diode and a second capacitor connected to each other at a second node and connecting the pair of second rectifier circuit output terminals, a third diode connecting the first node to one of the pair of second rectifier output terminals, and a fourth diode connecting the second node to one of the pair of first rectifier output terminals.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with government support under contract numberNNC16CA21C awarded by NASA. The government has certain rights in theinvention.

TECHNICAL FIELD

The present disclosure relates generally to power converters, and moreparticularly to power converters including a recirculating snubbercircuit.

BACKGROUND

Electrical power converters are used in multiple applications to convertpower from a first set of voltage and current characteristics to asecond set of voltage and current characteristics. Use of the powerconverters allows a single power source, such as a battery or otherstored energy component, to power multiple different electroniccomponents each of which may have a different power requirement.

One exemplary type of power converter, referred to as a step-upconverter, includes multiple stacked rectifier sections in order toachieve a higher output voltage. Each of the rectifier sections includesa bridge rectifier, as well as circuitry connecting the bridge rectifierto a voltage output. Previous high-voltage bridge rectifiers have beenconstructed utilizing silicon carbide diodes. However silicon carbidebased diodes are not suitable for usage in some environments, such asouter space, due to their sensitivity to radiation.

SUMMARY OF THE INVENTION

In one exemplary embodiment a power converter includes a first rectifiercircuit having a pair of first rectifier circuit output terminals and asecond rectifier circuit having a pair of second rectifier circuitoutput terminals, a snubber circuit comprising a first diode and a firstcapacitor connected to each other at a first node and connecting thepair of first rectifier circuit output terminals, a second diode and asecond capacitor connected to each other at a second node and connectingthe pair of second rectifier circuit output terminals, a third diodeconnecting the first node to one of the pair of second rectifier outputterminals, and a fourth diode connecting the second node to one of thepair of first rectifier output terminals.

In another example of the above described power converter the firstcapacitor is connected to the one of the pair of first terminals notconnected to the third diode and the second capacitor is connected tothe one of the pair of second terminals not connected to the fourthdiode.

In another example of any of the above described power converters afilter circuit includes a first filter inductor connecting the one ofthe pair of first terminals not connected to the third diode to amidpoint node, and a second filter inductor connecting the one of thepair of second terminals not connected to the fourth diode to themidpoint node.

In another example of any of the above described power converters eachof the first rectifier circuit and the second rectifier circuit are oneof a full bridge rectifier and a center tapped rectifier.

In another example of any of the above described power converters theeach of the first rectifier and the second rectifier comprises aplurality of silicon diodes.

In another example of any of the above described power converters eachof the first rectifier circuit and the second rectifier circuit rectifycurrents from transformers driven by a multi-phase power system.

In another example of any of the above described power converters eachof the first rectifier circuit and the second rectifier circuit issubstantially identical to each other pair of rectifier sections.

An exemplary method for reducing voltage spikes in a power converterincludes recirculating snubber energy through a snubber circuitcomprising a first diode and a first capacitor connected to each otherat a first node and connecting the pair of first rectifier circuitoutput terminals, a second diode and a second capacitor connected toeach other at a second node and connecting the pair of second rectifiercircuit output terminals, a third diode connecting the first node to oneof the pair of second rectifier output terminals, and a fourth diodeconnecting the second node to one of the pair of first rectifier outputterminals.

Another example of the above described method for reducing voltagespikes in a power converter further includes filtering a voltage betweena high voltage output node and a low voltage output node using a thirdcapacitor connecting the high voltage output node to a midpoint node anda fourth capacitor connecting the low voltage output node to themidpoint node.

In another example of any of the above described exemplary methods forreducing voltage spikes in a power converter the first capacitor and thesecond capacitor have approximately the same capacitance.

Another example of the above described power converters having amultiphase power system includes drivers that may be selectivelyoperated in a pulse width modulated mode or a phase shifted bridge mode.

In another example of the above described power converters, eachrectifier receives power from at least one transformer that has aprimary winding.

In another example of the above described power converters, the voltageacross each primary winding is limited by clamping diodes.

These and other features of the present invention can be best understoodfrom the following specification and drawings, the following of which isa brief description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a power converter including multiple stackedrectifier sections.

FIG. 2 schematically illustrates exemplary mirrored rectifier sectionssuch as could be utilized in conjunction with FIG. 1.

FIG. 3 schematically illustrates an alternate mirrored rectifier sectionfor utilization in a dual full bridge converter.

DETAILED DESCRIPTION OF AN EMBODIMENT

FIG. 1 schematically illustrates a power converter 100 includingmultiple stacked rectifier sections 110A and 110B. Each of the rectifiersections 110A and 110B includes a bridge circuit 120A and 120Bconstructed of diodes (see 220A and 220B in FIG. 2) connected to asnubber circuit 130A and 130B, a voltage output 140A and 140B, and anoutput filter 160A and 160B. Paired with the rectifier sections is acorresponding driver 150 that drives current through transformer 180 tothe bridge rectifier sections 110A and 110B. Driver 150 can be a singledriver or multiple drivers, depending on the needs of a givenapplication. Similarly, the transformer 180 can be a single transformeror multiple transformers, depending on the needs of the givenapplication.

The rectifier sections 110A and 110B are mirrored, and include a snubberrecirculation circuit 132 configured to pass a snubber current from eachsnubber section 130A or 130B to a corresponding mirrored snubber circuit130B or 130A. In order to make the bridge rectifier rad-hard (moreresistant to radiation), a bridge rectifier can be constructed utilizingsilicon based diodes instead of other diodes such as those made ofsilicon carbide. Silicon based diodes, however, have a longer switch-offtime, referred to as a reverse recovery time, and can cause spikes inthe output voltage of the bridge rectifiers. The snubber circuits 130Aand 130B operate to limit the amplitude of the spikes in the outputvoltage of the rectifier circuits 120A and 120B.

Snubber circuits 130A and 130B mitigate the voltage spikes caused by thereverse recovery time of the diodes in the rectifier circuits 120A and120B. Some existing snubber circuits mitigate the voltage spikes bydissipating substantial amounts of power, resulting in the generation ofsubstantial amounts of heat energy. In space applications, as well asany similar environment, the dissipation of the heat energy isdifficult.

Some alternative snubber circuits mitigate the reverse recovery time byrecycling the energy. These types of snubber circuits are referred to as“lossless” snubber circuits, despite some small amount of energydissipation. Some lossless snubber circuits utilize an active switchingof one or more transistors within the snubber circuit, and requireactive controls, which add complexity to the overall system.

In yet further existing lossless snubber circuits, additional inductorsare incorporated to allow for passive snubbing, however this increasesthe weight and cost of the snubber circuit.

In contrast to the existing examples, the mirrored snubber circuits 130Aand 130B of FIG. 1 avoid the need for added transistors or inductors byutilizing a mirrored construction. The output filter circuits 160A and160B are mirrored with respect to output filter inductor connections(see FIG. 2) such that the output filter inductor of filter circuit 160Ais connected to a low voltage connection of rectifier circuit 120A andthe output inductor of filter circuit 160B is connected to the highvoltage connection of rectifier circuit 120B. An output inductor of onefilter section 160A is connected to the negative output terminal 171 ofthe rectifier section 130A being connected to a midpoint node 172. Theoutput inductor of the other of the rectifier sections 110B is connectedto the positive output terminal 173 of the rectifier section 130B beingconnected to the midpoint node 172. This configuration can alternatelybe referred to as being connected in series between output terminals140, with the high voltage output of one being connected to the lowvoltage output of the other, in order to increase the output voltageacross the output terminals 140.

With continued reference to FIG. 1, FIG. 2 schematically illustratesrectifier sections 210A, 210B, such as could be used for the rectifiersections 110A, 110B of FIG. 1, in more detail. As with FIG. 1, each ofthe rectifier sections 210A, 210B includes a diode bridge portionconstructed of multiple diodes 222A, 222B arranged in a full bridgeconfiguration about a transformer coil 224A, 224B. In alternativeconfigurations, the full bridge rectifiers 220A, 220B can be replacedwith alternative rectifier types, such as center-tapped rectifiers andthe like. Similarly, the corresponding full bridge driver 150 (seeFIG. 1) could be replaced with any other type of driver.

Each of the rectifier sections 210A, 210B further includes asnubber/filter circuit 230A, 230B. In some cases, such as theillustrated example, a diode 231A, 231B can be included parallel to thesnubber/filter circuit 230A, 230B. The diode 231A, 231B is afreewheeling diode that improves the power converter efficiency byreducing power losses during the time intervals when the transformeroutput voltage is zero. Parallel to the first diode 231A, 231B is asnubber diode 233A, 233B and snubber capacitor 235A, 235B connected inseries with each other and connecting the positive and negative outputsof the bridge circuit 220A, 220B. As the rectifier sections 210 aremirrored relative to each other, the order of the snubber diode 233A,233B and the snubber capacitor 235A, 235B in the two snubber/filtercircuits 230A, 230B is reversed, with the snubber diode 233A, beingconnected to a high side in the first (upper) snubber/filter circuit230A, and the snubber diode 233B being connected to the low side in thesecond (lower) snubber/filter circuit 230B.

A node connecting each snubber diode 233A, 233B to the correspondingsnubber capacitor 235A, 235B is connected to the opposite snubber/filtercircuit 230A, 230B of the opposite rectifier section 210A, 210B via therecirculation circuit 232 comprised of snubber diodes 237A and 237B,with the node of the upper snubber/filter circuit 230A being connectedto a low side of the lower snubber/filter circuit 230B through snubberdiode 237B and the node of the lower snubber/filter circuit 230B beingconnected to the high side of the upper snubber/filter circuit 230Athrough snubber diode 237A.

Each of the snubber/filter circuits 230A, 230B further includes a filterinductor 234A, 234B. The filter inductor 234A, 234B of the uppersnubber/filter circuit 230A is on a low side of the snubber/filtercircuit 230A, and the filter inductor 234B of the lower snubber/filtercircuit 230B is on a high side of the snubber/filter circuit 230B. Eachof the filter inductors 234A, 234B is connected to a midpoint node 250.The midpoint node 250 is connected to each of the high and low voltageoutputs 240A, 240B via corresponding substantially identical capacitors252, such that the capacitors 252 define a voltage differential betweenthe high and low voltage outputs 240A, 240B. In some examples, theconnections used for the capacitors 252, as well as the rectifiersections 220A, 220B, are low impedance connections.

Mirroring the rectifier sections 210A, 210B, as described above,facilitates the inclusion of the snubber diodes 237A, 237B in therecirculation circuit 232. The snubber diodes 237A, 237B in turnrecirculate the energy from each snubber/filter circuit 230A, 230Bduring the process of clamping voltage spikes into the opposite,mirrored, snubber/filter circuit 230A, 230B. By recirculating theenergy, substantially less energy is required to be dissipated and noactive switching is required in the snubber/filter circuits 230A, 230B.The snubber diodes 237A, 237B in the recirculation circuit 232 suppressthe voltage spikes appearing at the outputs of full bridge rectifiers220A, 220B by transferring energy into the snubber capacitors 235A,235B. Diodes 233A, 233B reset the snubber capacitor 235A, 235B voltagesduring the time intervals when the voltages across transformer windings224A, 224B are essentially zero by transferring energy stored in thesnubber capacitors 235A, 235B to the output terminals 240A and 240B. Insome examples, the mirrored rectifier sections 210 are included in acircuit having low-inductance connections.

By recirculating the current through mirrored snubber/filter sections230A, 230B, as in the example of FIGS. 1 and 2, recirculation of energycan be achieved without requiring an additional recirculation inductorin each snubber/filter circuit 230A, 230B. This reduces the weight andcost, and can be particularly beneficial for applications having tightweight allowances and/or requiring substantial certification of eachcomponent, such as a satellite or other space based circuit.

In some applications, a greater range of operation at full output powerthan can be achieved via a single bridge driver 150 is required.Exemplary systems capable of achieving the greater full power operatingrange include dual full bridge converters capable of being operated ineither a known Pulse Width Modulation (PWM) mode or a known phaseshifted bridge mode.

FIG. 3 schematically illustrates an example dual full bridge converter300 including two full bridge drivers 350X, 350Y and two sets ofmirrored rectifier sections 310, 330. Full bridge driver 350X drives atransformer X, and full bridge driver 350Y drives a transformer Ythereby forming a multi-phase power system. Each of the sets of mirroredrectifier sections 310, 330 are substantially similar to the rectifiersections 210A and 210B of FIG. 2, with the exception that the bridgecircuits 320 are multi-phase bridge circuits that each rectify thevoltages from the two transformers X and Y, whereas the bridge circuits220A and 220B of FIG. 2 are single-phase bridge circuits.

Each of the mirrored snubber/filter sections 360A, 360B are connected toa corresponding bridge circuit 320, and are configured identical to thesnubber/filter circuits 230A, 230B illustrated in FIG. 2. To increasethe voltage between the output nodes 340, the two sets of mirroredrectifier sections 310, 330 are connected in series, with the low sideof 310 being connected to the high side output of 330, resulting in avoltage output that is about twice the voltage output of either mirroredrectifier section individually. In another example, only one of mirroredrectifier sections 310, 330 is connected between output terminals 340,similar to the arrangement shown in FIG. 2.

In yet further examples, additional rectifier sections, beyond the tworectifier sections 310, 330 illustrated in FIG. 3 can be utilized inseries, thereby providing additional voltage increases at the outputnodes 340. Similarly, multiple circuits of the types shown in FIGS. 1and 2 may be connected in series to provide a higher output voltage.

When high output currents at lower output voltages are desired, fullbridge drivers 350X and 350Y are operated in a PWM mode with the voltagewaveforms across transformers X and Y being out of phase. This causesthe currents produced by bridge rectifiers 320 to be equal to the sum ofthe currents produced by the individual secondary windings oftransformers X and Y that are connected to each bridge rectifier. Whenoperating in a PWM mode, the voltage between output nodes 340 isregulated by adjusting duty cycle of full bridge drivers 350X, 350Y.

When high output voltages at lower output currents are desired, fullbridge drivers 350X, 350Y are operated in a phase shifted bridge modewith the voltages across transformers X and Y being at nearly 100percent duty cycle, but with an adjustable phase relationship. Maximumoutput voltage occurs when full bridge drivers 350X, 350Y are operatedin phase and the voltages across the secondary windings of transformersX and Y add to produce about twice the voltage between output nodes 340than can be produced when operating in a PWM mode with the voltagewaveforms across transformers X and Y being out of phase.

In yet further examples, full bridge drivers 350X and 350Y includeinductors 351 and diodes 352. Inductors 351 can be used to facilitate aknown highly-efficient mode of operation commonly calledzero-volt-switching. When the duty cycle of the full-bridge driversfalls below 50 percent, inductors 351 can resonate with snubbercapacitors 361, which reduces the effectiveness of the snubbers inclamping the output voltages of rectifiers 320. Including clampingdiodes 352 in the full bridge drivers limits the voltage across theprimary windings of transformers X and Y to the input voltage suppliedto the bridge drivers, and thereby restores the effectiveness of thesnubbing while still allowing zero-volt-switching to occur.

Transformers can be designed to have high leakage inductances in orderto facilitate zero-voltage switching as an alternative to using separateprimary inductors 351, but the high leakage inductance implementationdoes not allow clamping diodes 352 to be used, and therefore it providesless optimal snubber effectiveness when the duty cycle is below fiftypercent.

In yet further examples, driver 150 in FIG. 1 may be implemented with afull bridge driver utilizing clamping diodes and an inductor in anarrangement to similar to diodes 352 and inductor 351 in 350X and 350Yto enhance the effectiveness of the snubber circuits in FIGS. 1 and 2for operating conditions in which the duty cycle is less than 50percent.

In some examples, filter inductors 234A and 234B are coupled as shown bythe polarity dots as shown in FIG. 2. In some further examples, thefilter inductors shown in FIG. 3 that have matching polarity dots arecoupled with the indicated polarities.

It is further understood that any of the above described concepts can beused alone or in combination with any or all of the other abovedescribed concepts. Although an embodiment of this invention has beendisclosed, a worker of ordinary skill in this art would recognize thatcertain modifications would come within the scope of this invention. Forthat reason, the following claims should be studied to determine thetrue scope and content of this invention.

1. A power converter comprising: a first rectifier circuit having a pairof first rectifier circuit output terminals and a second rectifiercircuit having a pair of second rectifier circuit output terminals; asnubber circuit comprising a first diode and a first capacitor connectedto each other at a first node and connecting the pair of first rectifiercircuit output terminals, a second diode and a second capacitorconnected to each other at a second node and connecting the pair ofsecond rectifier circuit output terminals, a third diode connecting thefirst node to one of the pair of second rectifier output terminals, anda fourth diode connecting the second node to one of the pair of firstrectifier output terminals.
 2. The power converter of claim 1, whereinthe first capacitor is connected to the one of the pair of firstterminals not connected to the third diode and the second capacitor isconnected to the one of the pair of second terminals not connected tothe fourth diode.
 3. The power converter of claim 1, wherein saidsnubber circuit further includes a first filter inductor connecting theone of the pair of first terminals not connected to the third diode to amidpoint node, and a second filter inductor connecting the one of thepair of second terminals not connected to the fourth diode to themidpoint node.
 4. The power converter of claim 1, wherein each of thefirst rectifier circuit and the second rectifier circuit are one of afull bridge rectifier and a center tapped rectifier.
 5. The powerconverter of claim 1, wherein the each of the first rectifier and thesecond rectifier comprises a plurality of silicon diodes.
 6. The powerconverter of claim 1, wherein each of the first rectifier circuit andthe second rectifier circuit rectify currents from transformers drivenby a multi-phase power system.
 7. The power converter of claim 6 inwhich the multi-phase power system includes drivers that may beselectively operated in either a pulse width modulated mode or a phaseshifted bridge mode.
 8. The power converter of claim 1, comprising aplurality of pairs of rectifier sections wherein each of the firstrectifier circuit and the second rectifier circuit is substantiallyidentical to each other corresponding rectifier section.
 9. The powerconverter of claim 1 in which each rectifier receives power from atleast one transformer that has a primary winding.
 10. The powerconverter of claim 9 in which the voltage across each primary winding islimited by clamping diodes.
 11. A method for reducing voltage spikes ina power converter comprising: recirculating snubber energy through asnubber circuit comprising a first diode and a first capacitor connectedto each other at a first node and connecting the pair of first rectifiercircuit output terminals, a second diode and a second capacitorconnected to each other at a second node and connecting the pair ofsecond rectifier circuit output terminals, a third diode connecting thefirst node to one of the pair of second rectifier output terminals, anda fourth diode connecting the second node to one of the pair of firstrectifier output terminals
 12. The method of claim 11, furthercomprising filtering a voltage between a high-voltage output node and alow-voltage output node using a third capacitor connecting the highvoltage output node to a midpoint node and a fourth capacitor connectingthe low voltage output node to the midpoint node.
 13. The method ofclaim 11, wherein the first capacitor and the second capacitor haveapproximately the same capacitance.